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Collaboration and Interoperability in Production Management of Ship-Building Industry
Prof. Xiaofei XU, Prof. Dechen ZHAN, Dr. Lanshun NIE
Business Cases for Enterprise Interoperability
School of Computer Science and TechnologyHarbin Institute of Technology, P.R. China
Business Cases for Enterprise Interoperability
Outline
Background and characteristics of ship-building industry
Typical collaboration / interoperability issues in ship-building production and supply chain management
Model-driven interoperability & methodology for enterprise application software systems in ship-building manufacturing
Case study in HUANGHAI SHIP-BUILDING Co. LTD in China
Business Cases for Enterprise Interoperability
Ship-Building Enterprise
Main Production Processes in a Ship-Building Enterprise
The HUANGHAI Ship-Building Factory
(黄海造船工厂)
Business Cases for Enterprise Interoperability
Ship-Building ProcessesTube /board handling
(Part machining) (管材 /板材加工 )
Dock fitting-out(码头舾装 )
Supply Hub-based logistics(collection and distribution)
(集配 )
Slipway fabrication and fitting-out(ship body assembling & system a
ssembling) (船台合拢和舾装 )
Purchase and inventory
(采购与库存 )
Block assembling and advance fitting-out
(Block assembling & system pre-assembling)(分段制造 /舾装 )
Business Cases for Enterprise Interoperability
Characteristics of Ship-Building Industry Production Characteristics:
Production modes: ETO (engineering-to-order), OKP (one-kind-of-a-product) and small batch manufacturing
The production process is divided into multiple stages. Very large products with complex product structure and
multi-functional systems. Thousands of materials, devices, and components come
from suppliers. The relationships across multiple enterprises, multiple
stages and multiple specialties are complicated. The lead time is very long while the due-date is tight.
Collaboration and interoperability inside and outside of enterprises are critical for ship-building.
Business Cases for Enterprise Interoperability
Block assembling
Slipway fabrication
Advance fitting-out Fitting-out
Body parts
manufacturing
Inventory management Unit
fitting-out
Collection &
distribution
Dock fitting-
out
Test
delivery
Dock
Purchase/sub-contract
Shop
Fitting-out com
ponent m
anufacturing
Warehouse Supply hub Land platform Slipway
Parts & components
pallet Blocks ship body finished
Finished ship
crucial devices supplier
anchor windlassBlower of engine roomMaterials & purchased component
Important component
supplier
Strategic supplier
Important supplier
Ordinary supplier
purchased components
crucial devicesImportant component
Materials & purchased component supplier
Customer
Physical View of ship-building
Business Cases for Enterprise Interoperability
Typical interoperability problems in ship-building industry
Interoperability between Product design and production engineering Production engineering and product manufacture /
assembly Batch manufacture and project oriented product
assembly Manufacturers and strategic suppliers( e.g. engine
suppliers, steel material suppliers) Manufacturers and sub-contractors Manufacturers and customers
Business Cases for Enterprise Interoperability
Typical interoperability problems in ship-building industry Interoperability requirements
Information level -- data exchange Order data Planning data Progress/Execution data Design data Quality Check data
Business level – process coordination Collaborative production planning Collaborative order processing Collaborative quality checking Collaborative order bidding Vendor Managed Inventory Event-based execution controlling and coordination
Business Cases for Enterprise Interoperability
Block assembling
Slipway fabrication
Advance fitting-out Fitting-out
Body parts
manufacturing
Inventory management Unit
fitting-out
Collection &
distribution
Dock fitting-
out
Test
delivery
Dock
Purchase/sub-contract
Shop
Fitting-out com
ponent m
anufacturing
Warehouse Supply hub Land platform Slipway
Parts & components
pallet Blocks ship body finished
Finished ship
crucial devices supplier
Materials & purchased component
Important component
supplier
Strategic supplier
Important supplier
Ordinary supplier
purchased components
crucial devicesImportant component
Materials & purchased component supplier
OKPOKPBatchBatch
PurchasePurchase
Customer
Requirements of Collaboration and Interoperability in Ship-Building collaboration
Collaboration with customer
Collaboration among body, system and crucial devices
Collaboration among blocks, system and important component
Collaboration between OKP and batch
Collaboration between collection/distribution and part machining
Collaboration between part machining and purchased material
Collaboration between block assembling and purchased components
Collaboration between body assembling and purchased devices
HANA(Project
Management Software)
HANA(Project
Management Software)HUITON CERP
(ERP software)
HUITON CERP
(ERP software)
UFIDA ERPUFIDA ERPSAPERP
SAPERP
Business Cases for Enterprise Interoperability
Typical interoperability problems in ship-building industry Barriers and difficulty in interoperability
Inconsistency in naming Multiple meanings for single terminology In-compatible data format Un-unified units for goods, currency, … Multiple standards of products and business/manufacturing
processes Mismatching between business processes Multi-production modes and business processes Heterogeneous platforms, languages and technologies of
existing IT system Un-transparency and low openness of existing IT systems
Business Cases for Enterprise Interoperability
Collaborative Production Management for Ship-Building
Phase Milestone Planning
3
4
5
Strategic suppliers
Important suppliers
Ordinary suppliers
Req. Planning
Pur. Planning
Pur. Planning
Body assembly Planning
Block assembly Planning (each)
Dock fitting-out Planning
System assembly Planning (each)
System pre-assembly PlanningUnit assembly
Planning
Part machining Planning
Part machining Planning
Collection & distribution
Planning
collaboration
collaboration
collaboration
3
542
2
Business Cases for Enterprise Interoperability
Collaborative Production Management for Ship-Building
Business Cases for Enterprise Interoperability
PSM model
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(7) (8)
(9) Block
Association
(10)
(11)
(12)
(13)(14)(15)
Business Cases for Enterprise Interoperability
Case study: HUANGHAI Ship-Building Co. Ltd in China
Passenger ro-ro ship (Weihai to Dalian) 1020 passengers/615m car lane
600TEU multi-purpose container ship Exported to Europe in batch
HUANGHAI SHIP-BUILDING Co. LTD
Business Cases for Enterprise Interoperability
CORP for HUANGHAI SHIP-BUILDING Co. LTD
CORP Management System Life cycle management for projects Tasks and WBS management Product and materials management Collaborative production planning and execution Organizations and resources management Planning/Scheduling and resource balancing Constraints management Procurement management Supply chain and subcontract management Graphic interaction supported decision making
Business Cases for Enterprise Interoperability
Benefits of the Ship-building Co. Improved requirements analysis for collaboration and interoperability of ship-bu
ilding manufacturing; Decreased term and cost for developing ship-building ESAs; Eliminated interoperability barriers
Information level: data standardization, technical data exchange, production planning data exchange, order execution data exchange, etc)
Business level: production planning collaboration, order processing, event-based coordination, etc.
Performance improvement: Rate of the orders (ships) which fulfill due-date is increased through collaborativ
e production planning and control; Utilization of key resources, e.g. slipway, is increased by means of collaborative
planning; Transactions between partners (e.g. order processing) is accelerated and the co
st is decreased; Information and data, e.g. technical data, business data and manufacturing data,
are exchanged more quickly.